U.S. patent application number 10/201035 was filed with the patent office on 2007-03-15 for system for manufacturing structures of cementitious materials.
Invention is credited to Christopher M. Hunt.
Application Number | 20070056223 10/201035 |
Document ID | / |
Family ID | 27113921 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070056223 |
Kind Code |
A9 |
Hunt; Christopher M. |
March 15, 2007 |
SYSTEM FOR MANUFACTURING STRUCTURES OF CEMENTITIOUS MATERIALS
Abstract
This disclosure is a system which includes processes, machines,
articles of manufacture and compositions of matter required to
construct a habitable structure comprised of a cementitious
product, preferably autoclaved aerated concrete ("AAC"), formed in
unique blocks, panels and beams. This results in an extremely
environmentally friendly habitable dwelling, residential or
commercial, which, due to the resultant synergy of embodiments,
when compared to a similar structure employing prior art and/or
current industry's standard materials and methods of construction,
is structurally superior and simultaneously yields substantial
savings in labor, time and costs.
Inventors: |
Hunt; Christopher M.;
(Atlanta, GA) |
Correspondence
Address: |
ROBERT M. HUNTER PLLC
P.O. BOX 2709
KAMUELA
HI
96743
US
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Prior
Publication: |
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Document Identifier |
Publication Date |
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US 20020174606 A1 |
November 28, 2002 |
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Family ID: |
27113921 |
Appl. No.: |
10/201035 |
Filed: |
July 23, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09784848 |
Feb 16, 2001 |
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10201035 |
Jul 23, 2002 |
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09741787 |
Dec 21, 2000 |
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10201035 |
Jul 23, 2002 |
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60183472 |
Feb 18, 2000 |
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Current U.S.
Class: |
52/79.1 ; 52/561;
52/592.6; 52/742.14 |
Current CPC
Class: |
F16B 25/00 20130101;
E04B 7/20 20130101; E04D 13/0645 20130101; Y02E 10/44 20130101;
H02G 3/38 20130101; E04D 2013/0486 20130101; F16B 15/06 20130101;
E04F 13/08 20130101; E04F 19/0436 20130101; E04B 1/74 20130101;
E04F 2019/044 20130101; E04D 2013/0813 20130101; E04B 1/04
20130101; E04D 2013/045 20130101; E04D 13/0648 20130101; E04D 13/08
20130101; E04F 19/00 20130101; E04D 13/064 20130101; E04B 5/04
20130101; Y02B 10/20 20130101; Y02E 10/40 20130101; E04B 7/02
20130101; E04C 2/049 20130101; E04C 2/521 20130101; F24S 20/66
20180501 |
Class at
Publication: |
052/079.1 ;
052/561; 052/592.6; 052/742.14 |
International
Class: |
E04H 9/00 20060101
E04H009/00; E04H 1/00 20060101 E04H001/00 |
Claims
1. In a method of constructing multi-sided, habitable dwellings
principally from pre-cut sections of a cementitious material for
building up from a foundation, said method comprising the following
steps to form a wall: a.) selecting a discontinuous first course of
blocks for cementing on said foundation, where said first course
blocks include at least a longitudinal slot, with said slots of
adjacent blocks aligned; b.) said first course having vertically
oriented blocks of predetermined size with a length of "X" so that
the top of said block closely equals the height of a door opening,
and a horizontal plane is formed along top of said wall section;
and c.) adding horizontally aligned beams on top of said primary
course, where a planar top surface is provided, and d.) said
openings in said wall are located on at least a one foot center
course and a predetermined structural component which is
architecturally finished on three sides bordering said opening.
2. The method according to claim 1, wherein said longitudinal slots
are aligned to define an internal continuous slot for receiving
utilities, including the further step of concealing the
longitudinal slot by covering with a subsequent course of
block.
3. The method according to claim 1, including the step of inserting
an arcuate configured insert into a receptive longitudinal slot at
any angled junction whereby to facilitate feeding of said utility
wiring through said receptive slots.
4. The method according to claim 2, including the step of providing
openings in communication with said continuous slot to house
utility electrical wiring outlets for access to said first living
level.
5. The method according to claim 1, including the step of
incorporating plural curved cementitious blocks in said
construction, and said curved blocks are fabricated into
predetermined curve shape prior to curing said cementitious
material.
6. The method according to claim 1, including the step of using
manufacturing blocks with plural internal voids, which when stacked
vertically align to continuously communicate from the base through
the upper most block, so that the desired temperature communicated
in voids is able to effect block's material and offset negative
effects of exterior temperature.
7. The method according to claim 1, wherein said final course of
cementitious material form beams having an enclosed longitudinal
void which can house air duct system so that when said beams are
joined a resultant continuous duct system is developed, and
openings are made through said beam material into said air duct
system as required for living space.
8. The method according to claim 1, including the step of providing
an uppermost course of blocks to support a roof, and said uppermost
course includes a top angled planar surface to define a roof pitch
for securing a roof system thereto.
9. The method according to claim 1, including the step of
overlaying and spanning said final course of beams with
predetermined floor panels which have a slot manufactured into said
panel, with said slots of adjacent panels aligned, whereby placing
rebar and mortar into said slots to provide a bond/ring beam which
is integrated into said floor panel, and at least an upper level of
embedded steel reinforcing stops shorter of a said panel end which
rests on said wall.
10. The method according to claim 8, including the step of adding a
stair system to join said multiple living levels, where said stair
system is comprised of steps of predetermined cementitious material
requiring no fasteners nor mortar, and a.) where said steps have a
slot manufactured into at least one end, which slot corresponds to
desired angle of stair's run, with said slots of adjacent steps
aligned, and b.) said wall also having a corresponding said slot so
that when a guide mechanism which length runs from near lower
living level to short of upper floor level is inserted into said
wall slot.
11. The method according to claim 9, including the steps of
securing a prefabricated, predetermined elongated shape similarly
shaped to a beam of cementitious product which may be reinforced
with steel and which can contain a continuous internal void
extending from end to end and is open at each end, said beam to
secured to said angled planar surface of cementitious material by
notching at least one part of either said beam and planar surface
so that scarfed joint engage and said beam and planar surface are
permanently fastened using only mortar and a metal helical
device.
12. The method according to claim 11, wherein said beam system
includes plural members which connect to each other so that a
structural support system results therefrom, a.) said beams having
corresponding notched ends which match for close to flush fit, b.)
said beams have a longitudinal cavity into which reinforcing cement
can be inserted, and c.) said longitudinal cavity aligns with other
beam's said cavity so that reinforcing and cement inserted therein
flows through individual beams and thereby make one monolithic
system.
13. The method according to claim 12, including the further step of
applying plural panels to said beam system, said steps comprising:
a.) using fasteners which requires no pre-drilling yet to allow
adhesive to be inserted into cavity formed by said fastening
device, and b.) said plural panels which are installed at an angle
are held in desired position by fastening device while adhesive
sets.
14. The method according to claim 13, including the further step of
applying cementitious roof panels comprised of exposed vertical
face having a chamfer with at least one sharply reversing and
upward angled groove which aligns with other said panels running
parallel to the length of said roof face, said cementitious roof
panels having reinforcing design modified so that at least one
section of reinforcing stops shorter of panel end and/or side of
other said sections, which resultant area void of reinforcing
allows panel to be modified by cutting a trough without
interference.
15. The method according to claim 14, including the further step of
applying a top surface face to said roof panels containing an
engraved trough running at a downward angle, such that said trough
of adjacent said roof panels are aligned so that moisture flows by
force of gravity through said trough.
16. The method according to claim 15, including the further step of
overlaying said roof panels with a polyester/nylon mesh fabric
featuring alternating sections of a tight mesh and a loose
mesh.
17. The method according to claim 16, including the step of
applying an elastomeric material to said mesh fabric, where said
elastomeric material penetrates only said loose sections to bond to
said roof panels, such that an air cavity is created between said
tight mesh and said roof panels, which predetermined said air
channel is of sufficiency for vapor permeability of roof panel and
runs unobstructed from lower starting position to near upper roof
ridge where it exhausts.
18. The method according to claim 2, including the step of
manufacturing curved blocks by a rounded mold inserted into a pan,
which rounded mold has predetermined arch and size compatible with
desired product and cooperates with said pan.
19. The method according to claim 2, including the step of
manufacturing curved blocks while said cementitious material is in
an uncured state, and using a computer controlled mechanism for
directing cutting wires through said uncured cementitious material
in a pattern which equates highest yield and least waste, which
results in curved cementitious blocks prepared for curing.
20. The method according to claim 7, including the step of
manufacturing elongated voids in a material by inserting a conical
shaped implement in such a manner that smaller end is imbedded in
material and larger end is at exterior of said material so that
implement can be easily removed with minimal resistance, where two
said conical pieces may be connected at smaller ends by having
threaded male and female ends, and said conical insert may have an
extending helical design so that when removed ridged indentations
are in cementitious material to assist bonding when said elongated
void is to be filled.
21. The method according to claim 20, including the step of joining
and simultaneously reinforcing two pieces of materials in one step
by adding a to said elongated cavity so when said liquid flows out
of said openings in annular wall and bonds to material and sets it
makes one monolithic, structurally reinforced piece from plural
pieces of materials.
22. The method according to claim 1, including the step of forming
a fire rated door manufactured of the same cementitious material as
said wall.
23. The method according to claim 1, including the step of adding
plural vertically oriented blocks on said foundation, where
adjacent said blocks exhibit an architectural surface finish,
including seams, requiring a minimum of final dressing.
24. In combination with a procedure for constructing a dwelling
consisting primarily of a cementitious material, where said
dwelling includes plural upstanding walls formed of cementitious
material and terminating in an upper surface suitable for
supporting a roof structure, a roof structure comprising: a.) at
least a first panel of cementitious material angled to and
supported by said upper surface, where said panel exhibits a planar
surface; b.) a polyester/nylon mesh overlying said planar surface,
where said mesh includes alternate sections of a tight mesh and a
loose mesh; and, c.) an elastomeric composition applied to said
mesh, whereby said composition adheres to said planar surface only
at locations under said loose mesh, while creating open channels
below said tight mesh.
25. A fastening member having particular utility in fastening
together a pair of panels of cementitious material, said fastening
member comprising: a.) a solid core member having an essentially
hour glass cross section; b.) an outer circular wall in contact
with opposing portions of said core member, and radially spaced
from remaining portions of said core member to define a chamber
therebetween, where said radially spaced wall portions include at
least one outwardly directed cut-out portion to expose said chamber
to the exterior; and, c.) an outwardly tapered head portion at a
first end of said core member, a pointed end at the opposite end of
said core member, and a radially directed helical member extending
along said outer circular wall from said tapered head portion and
said pointed end.
26. A fastening member for joining a cementitious panel to a wooden
submember, where said panel has a predetermined thickness, said
fastening member having a shank extending from a head portion with
a preselected diameter to a tapered remote end, a first helical
portion about said shank with a diameter greater than said
preselected diameter and extending along said shaft a distance
about equal to the thickness of said panel, and a second helical
portion extending over the remaining length of said shaft, where
the diameter thereof is less than said preselected diameter.
27. The fastening member according to claim 26, wherein said head
portion includes a tapered wall about said shank, and said tapered
wall includes a series of radial projections extending
therefrom.
28. An on site waste-free roofing system formed of panels of a
cementitious material for overlying a supporting, angled structure
extending generally upward at an angle of 45.degree. or 60.degree.
from a series of upstanding walls, said system comprising: a.)
selecting a series of rectangular said panels having a length of X
and a lesser width having a dimension divisible into X, b.) cutting
at least one said panel at an off site location at an angle of
either 45.degree. or 60.degree. to overlay on said supporting
structure, and, c.) continuing to overlay said supporting structure
with additional said panels in abutting relationship to one another
until said supporting structure is covered.
29. The method according to claim 14, including the step of
applying a curable, liquid base material on said roof panels, where
said material bonds to cementitious material, and when cured, is
waterproof, climate durable, chemical resitant, has a high modulus
of elasticity, has a high value of vapor permeableness, durable,
tintable for various colors, and bonds well to cementitious
material.
30. A dual operational fastening device for securing together
cementitious materials, said fastening device comprising: a.) shank
member having an annular wall, a core with opening at first end for
receiving material into which said fastening device is inserted,
and between said first core and an adjacent wall portion, a second
core extending to an opening in second end into which an adhesive
can be inserted, plural annular cut-out portions extending
tangentially from said annular wall connecting to first said core,
and plural connecting to said second core, and a helical thread
arrangement about said annular wall; and, b.) a broadened head
member at first end of said shank member, where said head member
includes means for removably securing a rotating hand tool and a
void where thread becomes head and end of head does not connect to
thread, said opening enabling fastener to counter sink.
31. The dual operational/fastening device according to claim 30,
wherein there are plural sections of angled tangential helical
thread sections protruding from a shank, to form said helical
thread arrangement, so that said thread sections assist the shank
staying centered in hole and on course during insertion to allow
flow around said thread sections and fill cavity between said shank
and wall of material.
32. The fastening device according to claim 31, wherein said
helical thread sections comprise: a.) thread sections wider at
shank and narrowing toward outer end, and simultaneously thread
sections are thicker at said shank and thinning toward the outer
end, and; b.) said sections are thinner at front leading edge and
thicker at second following edge and front leading edge from said
shank is shorter than back following edge.
33. The process according to claim 1, including the step of
inserting a device for fastening wiring into said longitudinal
slots which has a narrow opening near floor level and then rises up
into material so that slot is hidden from view, whereby said device
has, a.) long handle with shorter curved piece turned upward b.) at
end of said upward curve a mechanism for holding wire and
simultaneously feeding it to desired location.
34. The process according to claim 1, wherein an air duct system is
manufactured within a structural component of building and which
component, when placed in position, connects to other such
components so that the result is a continuous interconnected duct
system, and openings for serving rooms are made by penetrating said
structural component and duct system, with the result being said
system's air supply is sufficient to service the building. Process
according to claim 1 whereby waste cementious product is converted
into useful fertilizer by grinding into powder and adding any
additional nutrients, stabilizers required.
35. Process according to claim 21, wherein a machine crushes and
pulverizes waste AAC material into a size preferred for sewing into
soil for disposal and can act as a nutritional enhancer, soil
conditioner.
36. The process according to claim 31, including the use of a
cutting tool blade which is able to enter a material and cut it in
a desired direction without any surface preparation, said
comprising: a.) an elongate member of suitable saw blade material
having a width length, thickness, a first leading edge, a second
trailing edge, a first end and a second end; said first end being
provided with means to connect to a reciprocating mechanism; said
first leading edge having saw teeth extending from second end to a
first position adjacent the means to connect to a reciprocating
mechanism, and; b.) wherein said teeth are of uniform size from
first end until beginning of arc on leading edge near second point,
where teeth are of closer proximity along arc of first leading
edge, which arc terminates at middle point of said blade width,
which point is convergence of leading edge and second end and
trailing edge; and from second end trailing edge arcs away towards
first end with teeth of closer proximity but teeth are positioned
to be of neutral cutting angle having points perpendicular to
direction of blade length until arc ceases into straight line of
trailing edge which continues to first end; so that blade resembles
a sword with teeth along leading edge and teeth only on first
section of second point on following edge of point.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Ser. No.
09/784,848, filed Feb. 16, 2001 under the title "AUTOCLAVED AERATED
CONCRETE PANELS AND METHODS OF MANUFACTURING, AND CONSTRUCTION
USING AUTOCLAVED AERATED CONCRETE PANELS", and Ser. No. 09/741,787,
filed Dec. 21, 2000 under the title "METHODS OF MANUFACTURING AND
CONSTRUCTING A HABITABLE, CEMENTITIOUS STRUCTURE", by the inventor
hereof, where the contents thereof are incorporated herein in their
entirety.
FIELD OF THE INVENTION
[0002] This invention is directed to the field of manufacturing and
building structures, such as dwellings, and more particularly to a
system for manufacturing structures of cementitious materials of an
autoclaved aerated cementitious concrete.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a system for manufacturing
structures of cementitious materials, and to unique techniques for
finishing various features of the structures. The construction
industry is basically unchanged in materials and processes for
hundreds of years, while during this same time most other
industries have been revolutionized. The consequence is that there
is vast room, and need, for improvement in the construction
industry, for the lack of improvement has resulted in escalating
costs and a compounding of negative impact on the environment.
[0004] The construction industry has sought alternative building
The construction industry has sought alternative building materials
and techniques in order to limit the traditional expenses of
construction. The costs include the high energy costs of
manufacturing, increasing scarcity of quality materials and the
rising cost of available materials, and increasingly expensive
construction labor. Regrettably, the majority of solutions employed
so far have only resulted in an increasingly inferior quality to
finished product. Consumers desire to lessen the negative
environmental impact (i.e.: deforestation, mining and pollution
from manufacturing) and negative health effects (i.e.:
fluorocarbons and other harmful gases, mold from decay) of some
building materials. These factors have forced home builders in
particular to consider new construction materials. These new
materials must be versatile, easy to use, durable, and energy
efficient.
[0005] An alternative to the conventional building materials is
what may be called Autoclaved Aerated Concrete, hereinafter
referred to as "AAC". AAC is superior to current building materials
and is extremely environmentally friendly. That is, the teachings
hereof will substantially reduce global warming by preserving
forests. While this invention applies to any cementitious material
which can employ the teachings of this invention, AAC is a
preferred material and the further description will be so
limited.
[0006] AAC was invented in the early 1900's and consists of a
mixture of cement, aluminum powder, lime, water and finely ground
sand. This mixture expands dramatically, and this "foamed" concrete
is allowed to harden in a mold, followed by curing of the hardened
mixture in a pressurized steam chamber, or autoclave. Commercial
production of AAC began in the 1930's, and presently more than 31
million cubic meters have been produced worldwide.
[0007] Compared to wood, steel and standard concrete, AAC is a
clearly superior material as it is fire proof, termite proof, self
insulating, sound insulating, non decaying and does not rust.
Compared to concrete, AAC weighs 30% less than traditional concrete
masonry units. Additionally, AAC is well known as an
environmentally friendly construction material with certain
manufacturing plants receiving recognition as being "Green
Factories." Compared to the energy consumed in production of many
other basic building materials, only a fraction is required to
produce AAC. Raw materials consumption is very low for the amount
of finished product produced. In the manufacturing process, no
pollutants or toxic by-products are produced. AAC is also
completely recyclable.
[0008] AAC is an inorganic material that contains no toxic
substances. It does not slowly decompose nor emit a gas. Since AAC
is both a structural and insulation material it allows the
elimination of other materials that can contribute to poor indoor
air quality. Due to its inorganic structure, AAC also eliminates
the food source condition required to be present for microbial
growth to occur. Thus, AAC is resistant to water penetration and
decay. As it is a solid cementitious building material, insect
(roaches, ants) and rodent (rats, mice) infestation is impossible
within walls and floors as there are no cavities as now occurs in
standard frame construction.
[0009] Further, AAC is non-combustible, so in the case of fire it
can help prevent the fire from spreading to other rooms. During a
fire, no toxic gases or vapors are ever emitted from inorganic AAC.
As building methods using AAC include using solid blocks and panels
with very simple connection details, the ease of construction helps
to ensure a monolithic, highly fire-resistant wall.
[0010] AAC buildings, as described by this invention, can be very
energy efficient. This efficiency is due to a combination of high
R-value, thermal mass and air-tightness. AAC is the only product
currently available that meets Germany's stringent energy codes
without added insulation. It is well documented that the R-value of
a mass product need not be as high as that of light frame
construction, to perform thermally efficiently.
[0011] AAC products are unfinished. Depending on the building use
or the aesthetic requirements, AAC may be coated with an exterior
surface finish of approved stucco, stone, brick-veneer, wood siding
with furring, or a combination thereof. On the interior AAC usually
has sheetrock installed over furring strips due to utilities and
numerous joints of blocks.
[0012] While the construction industry recognized certain
advantages in the use of AAC components for building, no system
exists to effectively take advantage of the superior qualities of
AAC in a cost effective manner. In fact, even though AAC is itself
considered a vastly superior construction material than current
construction industry standard wood, steel and/or concrete, the
prior methodologies employed in AAC construction cause ACC to be so
much more labor intensive and costlier than current standard
construction materials, that the negatives of prior methodologies
of AAC construction basically outweigh AAC's inherit advantages and
so prohibit AAC from being considered as a viable alternative. The
teachings of this invention not only eliminate these prohibitive
negatives, they so facilitate the construction of AAC habitats that
AAC habitats now can be built in less time and for less end use
cost than conventional materials, with the underlying theme being
the construction industry's prerequisite "simpler, better, cheaper"
motto.
DESCRIPTION OF PRIOR ART
[0013] Despite the early development of AAC as a potential building
material, there is little in the patent prior art. There is a
recent patent, U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994,
which relates to only a manufacturing process using a modified
composition for AAC. While it is helpful in finding a beneficial
use for what is now a waste product, it in no way addresses any of
previously mentioned problems prohibiting AAC's market acceptance.
So while it is helpful in finding a beneficial use for what is now
a waste product, it fails in that AAC still has no way of being
successful in construction industry, so it is dependent upon this
invention for its success.
[0014] The present invention is a synergistic whole, completed
structure as a precast concrete system and may appear similar to
U.S. Pat. No. 5,761,862 to Hendershot et al., Jun. 9, 1998, but
that is due only to also emulating a residential structure, as the
very nature of material used and processes employed are
incompatible. Of the searched Prior Art, it is the closest, yet
upon closer inspection it is vastly different in every respect.
Hendershot uses a very complex steel reinforcing and joint system,
bonding system requiring flared coil loops and sheebolts,
structural bearing system requires complex precast steel mechanism,
and a hip roof cannot be constructed as even simple dormers are
reduced to nothing more than exterior architectural accents placed
over constructed roof All prior art requires great quantities of
steel reinforcing, steel brackets, mechanisms and/or laborious,
precise manufacturing processes facilitating site construction.
[0015] Wall process: U.S. Pat. No. 6,098,357 Franklin et.al., Aug.
8, 2000, cites well the problems of all prior art's various block
wall systems. Yet, itself requires additional materials for
architectural finish, its process of uniquely formed and
dimensional blocks greatly exceed the minimal three block vertical
height of current art, requires additional steel anchor system,
does not even address the problem of utility locations in walls and
it is composed of inferior material lacking all the innate
attributes of AAC. Referring again to U.S. Pat. No. 5,286,427,
Koumal, Feb. 15, 1994, fails in its design in FIG. 5 and
description to be so unfeasible that they are only intended as an
example of product and no way intended as representative of a
construction system. The present invention's processes and articles
of manufacture allow for the temperature transfer system which
heats/cools the wall for specific purpose of countering exterior
environment's temperature effects on wall material. Most prior art
is concerned with radiant heating of interior and not stabilizing
the insulate properties of the wall's material, therefore their
design and processes are either inadequate or unfeasible.
[0016] In this invention's support beam system for roof, etc., the
prior art of U.S. Pat. No. 4,285,179, Goidinger, employs a
lightweight cementitious material in panel form that has
longitudinal cavities that are filled with heavy standard type
concrete and optionally reinforcing steel which makes vertical wall
panels load bearing. The roof beam system hereof with optional
reinforcing channel, is novel for following reasons: 1) Goidinger
is specifically vertical walls, 2) due to incompatible uses are
structurally and dimensionally dissimilar, 3) while Goidinger has
internal cavities formed by sandwiching formed wide panel halves
together, the solid rectangular beams hereof have much thicker
exterior AAC for distinct purpose of receiving "R" screws or
similar fasteners and can be shaped in angles to equal roof panel's
pitch, 4) beams can have corrugated shaped channel system adding
strength and additionally preventing added cement from adhering too
quickly to dry sides preventing added cement from adhering too
quickly to dry sides and clogging cavity and therefore preventing
it from being completely filled, which can be a serious failure
problem of Goidinger, and lastly 5) has a utility channel. It is
unobvious as no other prior art has specific use of: 1) weaker
material used for a structural purpose of receiving fasteners, 2)
used solely for structural, load bearing beams spanning space, as
without the present invention screws and interlocking beam ends it
was almost impossible to engineer such a system for practical
application. In regards to beam's interlocking ends, there is no
prior art in cementitious material, but U.S. Pat. No. 4,409,763,
Rydeem, Oct. 18, 1983 uses a great wood system of one vertically
oriented dowel to secure a plurality of intersecting beam ends onto
a post, but has no method for a suspended, self supporting, load
bearing beam system spanning space. Again, all other prior art in
cementitious materials employ complex, heavy-duty steel brackets,
support/reinforcing, etc., and still cannot accomplish process of
invention.
[0017] Presently, there is great waste in conventional roof
construction to accomplish the desired architectural look of
multiple hips, ridges and valleys. In U.S. Pat. No. 5,794,386, to
Klein, Aug. 18, 1998, there is taught a roofing system. More
specifically, the patent is directed to a roof panel for sloped
roofs and includes a self-supporting reinforced plate of
cementitious materials, wherein the reinforcement above the plate
has bars running along the slope of the roof. Compared to the
present invention it is a very complicated, costly combination of
cement and steel reinforcing.
[0018] Another aspect of this invention's roof system is its
gravity induced internalized gutter system. All prior art with
internalized gutter systems for pre-cast concrete panels (Meyers,
U.S. Pat. No. 723,175; Novoa, U.S. Pat. No. 3,603,052; Rook, U.S.
Pat. No. 6,006,480) rely on force from additional moisture to push
accumulated previous moisture out of a level, straight gutter
system, and the results are problems of residual moisture and
accumulated debris causing damage to gutter system and structure.
U.S. Pat. No. 929,684, Mills & Taylor, Aug. 3, 1909, is an
example of common design deficiency allowing moisture to run down
the face so that debris residue leaves streaks and moisture angle
water deflection system.
[0019] No prior art addresses either processes or compositions of
matter of this invention's roofs water proofing system. Only U.S.
Pat. No. 5,981,030 Haupt et al, Nov. 9, 1999 has a figure similar
in appearance, but by closer inspection thereof, and by reading the
detailed description, the following incompatibilities, physical
differences and new unrelated processes become clear: 1) is not
used for waterproofing but rather water retention which defeats
process of facilitating removal of vapor from AAC roof panels, 2)
its process is a solid mass for water retention and not air
cavities for venting, 3) the materials used are completely
different and incompatible, 4) while absorber (4) is held in place
by fleece (1) and joined to base material (5) by a laminate (2),
there is no continuity as absorption is confined to small areas
(6), the laminate does not coat entire product but on specific
areas (6), the fleece has no structural purpose other than to hold
absorber (4), 4) quilted absorber areas are of various sizes and
perforated coating film contradict teaching of this invention.
There is no prior art, nor proven commercial product for matter of
composition which will be a satisfactory alternative roof water
proofing system. Heretofore AAC roofs were forced to use
conventional roofing materials that are labor intensive, costly,
add tremendous weight to roof system, and are for the most part
environmentally harmful.
[0020] While there are pre-cast roof panel systems in the prior
art, none could emulate the ridges and valleys of contemporary
rooflines. Current methods of wood construction use nominal
4'.times.8' sheets of processed wood, i.e. plywood, which results
in large amounts of waste.
[0021] When an existing wood structure requires roofing
replacement, prior art systems had no satisfactory way to
permanently fasten AAC panels to the wood rafters, nor was there a
roofing product light enough for wood structure to support both the
AAC panels followed by the heavy roofing material.
[0022] In areas requiring sound control, such as near airports,
etc., there was no cost effective way to sound proof the roof of a
house while simultaneously making it energy efficient and
environmentally friendly.
[0023] For multi-story buildings, Prior Art U.S. Pat. No. 723,175,
Meyers, Mar. 17, 1903 is only prior art of a remote reference to
ring/bond beam floor panel and corbel ring/bond beam as the patent
shows a wall with floor and roof being incorporated into a single
monolithic unit without a separate ring/bond beam. The processes it
employs of a mold into which concrete is poured is incompatible
with this invention which uses pre-cast pieces.
[0024] U.S. Pat. No. 5,143,498, Whitman, Sep. 1, 1992 has a screw
with a chamber with laterally disposed openings that are to
disperse liquid sealant. The Whitman screw has a single chamber for
dispersing sealant which attaches to rubber material as material
presses against openings and exterior wall of screw's shaft, which
may work for it as it has a screw head which remains exposed
outside material and a tight configuration of threads ideal for
rubber. U.S. Pat. No. 5,249,899, Wilson, Oct. 5, 1993 employs a
shaft for dispersing an adhesive through openings located in a
recessed thread which works for it since it is used for pre
drilled, machined metals, but would be useless in cementitious
product as dust would clog. U.S. Pat. No. 5,516,248, DeHaitre, May
14, 1996 has a plurality of outwardly projecting serrations which
burr into the work piece for self locking, but the design is
limited to that sole use and design is counter productive in a
cementitious material. Standard rebar requires drilling a hole,
inserting rebar and then mortar, and in method cannot hold inclined
pieces in place.
[0025] While there are many references to prior art for tools of
routing and reciprocating saws with plunging process, U.S. Pat. No.
5,682,934, Rybski, Nov. 4, 1997; U.S. Pat. No. 5,240,052, Davison,
Aug., 31, 1993 references are closest related to this invention,
yet they are more complex, confined to independent actions
performed on individual pieces at a work station requiring pieces
to be later combined with other pieces at site, and are restricted
by complexity of guide or design's dimensional limitations as
systems lose feasibility when enlarged so cannot create and finish
large openings and/or architecturally finish large surfaces of
permanent placed, vertically positioned structural material.
[0026] U.S. Pat. No. 721178, E. P. Golden, Feb. 24, 1903 does not
apply to joint finishing tool as it is for process of removing a
prescribed depth of material surface and not just cleaning off an
excess of a different material from surface, the patent shows it
has two wheels to each side of blade vs. one elongated wheel which
serves additional function of smoothing out and imprinting residual
material, FIG. 4 shows pressure is exerted on rear positioned blade
vs. on rear rolling pin like wheel which drives neutral front
positioned blade.
[0027] U.S. patent to Planchon, Mar. 22, 1995 shows a reciprocating
saw blade with unique tip for starting a hole and cutting, but not
a good method for holding tool in position while blade starts hole
as one of problems will be maintaining blade in starting hole
without opening template guide and tool guide arms.
[0028] It is now understood that all prior art and standard
industry methodologies employ complex, expensive and
labor-intensive combinations of concrete with heavy-duty steel
reinforcing and structural support systems/beams that employ
complex steel fastening systems.
SUMMARY OF THE INVENTION
[0029] Present invention was forced to develop new processes,
machines, articles of manufacture and compositions of matter for
the effective use of cementitious AAC panels, blocks and shapes for
the construction of environmentally friendly habitats. Upon review
of Introductory Figures of Prior Art/Current Methodology, it will
be noticed that there is not one component that is not either
completely unique or modified in such a manner that the resultant
process is completely new. Entire structural habitat can be
constructed of cementitious product without use of steel support
beams, interlocking steel brackets, bolts or other common steel
parts (only rebar as building code requires), gutters, down spouts,
wood trim, casing, and /or molding, nor conventional roofing
materials, yet has the same degree of functionality as a
conventional dwelling with these features.
[0030] It was discovered that large, precisely dimensioned elements
of AAC allow for rapid construction as compared to conventional
brick and CMU (concrete block). Their greater dimensional accuracy
requires less on site adjustment. The combination of large size and
dimensional accuracy allows greatly increased productivity. Due to
the light-weight of AAC, reduced equipment demands are
realized.
[0031] The walls employ processes of minimizing vertical blocks.
There are two wall block sizes: mini-wall and wall block. Their
differing contributions to wall process will be detailed later. But
each wall block has invention's utility channel and is coordinated
with other blocks of invention's processes. Each block serves a
specific function in the wall itself as well as replacing as many
as four separate items required in current construction.
[0032] Invention's process of constructing walls of cementitious
blocks, such as AAC, is superior in minimal quantity of two
vertical components (wall block and top block--with casing block
for openings) and three vertical components (base block, mini-wall
block and top block--with casing block for openings), structural
pieces are pre-finished and simply installed as specified (base,
casing, top, crown), are constructed so utilities are inside walls
which have finished surface including architectural effects ready
for painting.
[0033] Openings for windows and doors use present art's casing
block with utility chase system and are dimensionally located with
components of this invention's process on one foot centers so
entire dwelling is an unified dimensional process thereby a
standard 8' high wall uses three components vertically and
horizontally can have virtually no waste. Invention's alternative
process of wall block system allows for all advantages of vertical
three block system with less labor as requires only invention's
utility channel slot at base which coordinates with utility channel
in other articles of manufacture such as casing blocks, etc. To
fully appreciate wall block system, to be cost effective in
manufacturing and field requires adding 6'' of length to AAC
industry's standard 20' slurry mold so three full lengths of 82''
wall blocks and matching casing blocks can be produced without
waste.
[0034] Returning to the current manufacturing capabilities, casing
blocks, etc. are horizontally dimensional for 1' and 2' center
construction. Single wall block is not called a panel as steel
reinforcing is not required which is substantial savings. Casing
blocks can be omitted and architectural effect added into wall
blocks and Top Block using invention's tools.
[0035] One example of an advantage of this invention over prior
methodology of AAC construction and prior art of CMU block, by
using the traditional solid blocks and/or panels there was no good
means to provide a finished interior wall without first using wood
furring strips and externally positioning electrical utility boxes
and wiring which further meant that wood studs and sheetrock or dry
wall panels were required; consequently basically requiring two
wall systems, or, alternatively routing and then inserting conduit
and then having to repair walls. All this added substantial extra
labor and material costs to the construction using AAC panels and
blocks. Current art's internal "utility channel" system allows all
utilities to be placed inside wall during construction and with
special "fishing curve" and "multi conduit" inserts allow utilities
to be placed within wall even after construction. The current art's
utility channel system, inserts and architectural finish provide a
structurally superior finished wall with surface simply requiring
paint and/or wallpaper as a normal finished sheetrock wall. Current
art eliminates all labor and/or forest materials of constructing an
additional wall system. Current art even eliminates need for
finished wood trim by architecturally finished blocks and
invention's tools that are designed to finish vertical, and even
upside down, surfaces. Current art's unique wall block system has
not only saved labor and materials as compared to conventional AAC
construction, it has actually made AAC less expensive and labor
intensive than standard construction materials and
methodologies.
[0036] The top course of a wall is constructed using top block/beam
that is dimensionally sized at +/-16''. It can be manufactured as a
block or a continuous beam, as it can be reinforced and even house
invention's air duct system. An industry standard 2' wide panel can
be substituted for top block, as wall block's unique shape is
critical for process.
[0037] A common design problem is resultant gap between the top of
a wall where it meets a sloped roof. The crown block with sloped
top fits perfectly into this space and allows for architectural
continuity. The crown block allows for sloped roofs and, if left
with a level top, even additional floor systems to rest on
architecturally finished structural components.
[0038] As previously noted, AAC buildings can be very energy
efficient. A recent study in the U.S. shows that an 8'' AAC wall
performs better than a conventional 2''.times.6'' wood stud wall
system with R-30 Insulation. AAC is ideal for variable temperatures
so that the outside temperature is dissipated by change before it
can permeate block and effect interior. The only disadvantage to
AAC's thermal insulate value is in a location where there are
continuous days of below freezing temperatures as occurs during
winters in northern United States and Canada, the cold eventually
permeates the AAC block. A test in Pennsylvania not using current
art for AAC, showed when AAC is exposed to a constant temperature,
such as freezing, over a period of time, it was found that a
winter's heating expense was the same as a standard 2.times.4 wood
frame home. This is one reason why AAC plants are presently located
only in Southern areas, an ideal climate of moderate, fluctuating
temperatures. Current art solves this problem through its
temperature transferring system manufactured in blocks and panels
and is available for climates requiring it. Warm or cool air is
simply circulated through holes in exterior half area of blocks.
The manufacturing of transfer channels is unique in that the tubes
inserted into the pan mold are two conical tubes with threaded
ends, one male and one female, which after curing are separated by
tool which is inserted into larger end and engages indentations and
is twisted to unscrew tubes. The purpose for conical shape is
ability to ease withdrawing longer sections of pipe from
cementitious material thereby enabling even 20' lengths to be more
easily removed.
[0039] The utility chase and block wall systems are only a few of
the numerous other embodiments and claims of this application which
each individually and combined, address specific areas of
improvement in AAC construction.
[0040] The structural beam system is placed on walls and is unique
in being constructed of reinforced AAC or alternatively can be
comprised of two cementitious materials, having a center fiber and
steel reinforced concrete and outer casing of AAC which accepts the
screws hereof, flange bar and/or hollow bar, which are used to
fasten roof panels to beams.
[0041] The beams can have reinforcing center formed by two halves
with longitudinal slots joined and filled, even HVAC duct and a
utility channel can be placed inside so trades simply pierce AAC
where desired openings are to be located.
[0042] Currently the AAC industry does not use AAC for its roof
systems in residential application because the required structural
steel support beams, etc., rendered it impractical, so industry
methodology is to attach a conventional wood and asphalt shingle
roof on top of AAC walls. Current art is able to feasibly employ an
entire AAC roof system with no steel I beams, support columns,
brackets, braces, bolts, etc. The structural beam system allows for
all conventional roof designs to be possible, which was previously
thought unfeasible with cementitious products due to weight,
fastening systems and difficulty of working with product.
[0043] Invention's roofing system maximizes AAC's innate attributes
by combining structure, insulation, gutter, water deflection, and
waterproofing all in one. One of the more important ideas of
invention is the AAC roof panel's waterproofing system. The AAC
roof panels employ current art's cost effective waterproofing
systems, both systems are environmentally friendly products to
manufacture, and the consumer use of either invention will relieve
landfills of 100,000 of tons of current industry asphalt shingle
refuse currently being dumped every year. The current art is
designed to never have to be replaced, only re-coated every 10+
years. Roof repairs are easily discovered and can be repaired by an
unskilled homeowner. Professional roofers will appreciate ease of
application. Both systems not only waterproof, but also remedy
problem of AAC's requirement for vapor permeability (to be able to
"breathe") so moisture build up does not occur inside habitat.
These are only systems known to be able to be applied directly to
roof surface and still facilitate vapor permeability.
[0044] The indivisible internalized gutter system is similar in
that it eliminates costly additional gutter systems that must be
maintained and replaced. The water deflection system not only adds
aesthetic enhancement but provides process through its unique
reverse (upward) angles to cause water to separate from face
preventing unsightly runs as well as help dissipate negative effect
of water runoff. The gutter down spout box eliminates need for
unsightly down spouts and add architectural accent. Because of new
roof system interior space is greatly increased by volumes as attic
insulation is not required. insulation is not required.
[0045] The new beam and panel roof system of this invention greatly
increases interior space by creating habitable areas in roof vaults
that previously were inhospitable, namely wasted attic space.
[0046] The waste-free system taught herein allows for flexible
custom application of AAC roof panels so contemporary roof lines
are realized. The waste-free roof system can be implemented for
hips as well as valleys.
[0047] When teachings of this invention are applied to install AAC
panels over existing roof structures, they overcome weight,
fastening and aesthetic concerns. An unanticipated use may be for
sound proofing by removing existing asphalt shingles, etc., and
screwing AAC panels directly over wood decking into rafters. The
unique screw for installing AAC panels into wood have wide flanges
in the area to cover the AAC material. The wood threads on the tip
are used to permanently secure the panel into the wood. The threads
actually help to control the depth of penetration of the screw,
followed by a light weight, environmentally friendly coating.
[0048] When constructing multiple stories, invention's ring/bond
beam floor panel eliminates several time and material consuming
steps. The floor panel has unique modification of top row if
reinforcing stopping 1' short of panel end (same as for roof panel
for gutter system). This allows invention's ring/bond beam slot to
be manufactured. Construction is simply placing beam on top of wall
with panel end flush to exterior wall face, inserting required
rebar into slot, installing the screws hereof through slot into
wall below, which screws engage other reinforcing in panel. The
heads of screws can be left protruding into slot and rebar tied to
them, then add mortar and immediately next course of block, and
continue on with next wall. This eliminates all the following
current methodology: 1) place panel end short of face of exterior
wall, 2) mortar a block flush to face of exterior wall leaving a
gap between panel end and block, 3) place rebar into gap and add
lots of mortar, 4) wait day for ring/bond beam to set and then
continue construction.
[0049] An alternative improvement in time and costs for multiple
story construction is method of constructing walls without laying
floors or roof until all walls are constructed. This method saves
cost trips which can add up to thousands of dollars, as well as
additional costs of down labor time for wall crews waiting for
crane to finish, The method is for a crown block to be used that
protrudes into interior area and forms a ledge for supporting floor
system. When all walls are constructed crane simply sets all floor
panels into interior area and roof panels onto crown block ledge,
all in same day by use of invention screws. The crown blocks serve
as ledge as well as architectural finish.
[0050] Corbel ring/bond beam is similar, as wall face is routed,
using invention's routing system, to receive a pre-cast, reinforced
AAC beam. Simply mortar and fasten into place using the screws
hereof and then floor or roof can be set on corbel ring/bond beam.
This process using unique articles of manufacture allow for quick,
strong permanent placements of floor and roof panels where before
an entire wall assembly system was required.
[0051] Stairs providing access between floors are now able to be
cost effectively constructed of cementitious material that
immediately gives fire protection. Stairs will not creak and have
benefit of muffling a lot of the noise transmitted by standard wood
stairs. Current methodology for constructing stairs, especially
curved and suspended stairways, require a very skilled craftsman,
but now unskilled labor can construct a superior stairway in less
time.
[0052] The invention screw is an indispensable article of
manufacturing which facilitates many of invention's processes. The
auger type invention screw now makes it possible in one motion to
set steel reinforcing into cementitious product without
pre-drilling a hole and having to wait for mortar to set. An
example of one advantage, a roof panel set on a 12/12 pitch can be
set in place with invention screws into wall and invention's beam
support system and left with no other support. The invention screw
locks all pieces together with threads and counter sunk head. An
entire roof system can be installed, then the worker comes back and
fills all invention screws with mortar at end of day for them to
set up overnight. Next day roof is waterproofed.
[0053] A few nuances of the invention screw are advantage of
invention's flanges on screw head are to gouge out AAC so head can
counter sink and simultaneously help lock in place. Unlike any
other screw, the invention screw has the ability to be drilled very
close to surface without breaking AAC apart because of its auger
process alleviating pressure that a standard solid shaft creates.
The chambers' unique design actually allows mortar and screw
process to make one monolithic piece of separate pieces in one
step.
[0054] Invention's alternative, the flange bar, is a modified rebar
with most of the advantages of the invention bar except it requires
pre-drilled holes. Invention's flange bar allows direct bonding and
reinforcing as code requires with superior results of centering
rebar in hole, allowing mortar to fill hole around rebar, secure
rebar directly to cementitious material, hold cementitious pieces
in place by flanges imbedded in walls of hole preventing shifting
movements, flanges greatly increase holding power. The "R" screw
has advantage of one step process while flange bar has less
expensive manufacturing costs and can be cut at any length at a
point removed from a flange so that a hammer drill can be placed
over shaft and the shaft used as a bit.
[0055] A hybrid of both the invention screw and flange bar is
hollow bar which combines best attributes of both inventions into
one unit. It uses invention's cutting device that in cutting uses a
crimping action that results in serrations which through bar's
twisting action grind AAC into dust and force into hollow core. It
has a helix-action with auger flanges which leaves slots for
special epoxy (not regular mortar) to be inserted around bar.
[0056] By use of the invention's nail screw, the result is
synergism in that now one item replaces two previously separate
processes with the benefits of both and modifications eliminating
detriments. A problem with fastening items into a cementitious
product is that the cement is not like wood which holds by a
constant expansion pressure upon inserted object, cement holds by a
gripping and/or binding to concrete. Therefore when object is
removed it can rarely be reinserted into same hole with effective
holding power. The invention screw overcomes this problem by
gathering dust in its tip which binds, by prongs near head which
pierce and hold, torque more pressure via screw head and by ability
to reinsert finish nail in hollow shaft and re-explode tip. While
prior art, such as Helifix, has advantages of piercing and twisting
to hold in AAC, it requires long sections of shaft to work
effectively and still wiggles and can work free without mortar. The
screw hereof has variable degrees of hold, and via nail exploding
tip, has unique process of being permanently set and still retain
ability to be removed without damage to AAC or fastener and then
even reused in same hole.
[0057] Door slabs can be composed of AAC giving great fire safety
and sound insulation to rooms. As AAC is non-combustible, current
art even has an AAC door that is unique in allowing a four-hour
fire rated wall having a specially designed opening.
[0058] Tools biggest advantages are ability to be used on vertical
plane surface and enabling unskilled workers to make finished
openings and other modifications in thick walls, as well as
finished trim designs. Most of the tools combine steps so that what
required two or more tools and several processes in prior art can
now be done with invention's machines, articles of manufacture and
processes with one tool and in one step.
[0059] Invention's air duct system uses AAC insulate characteristic
and duct's structural reinforcing for unexpected result of a
manufactured structural component: 1) an internal duct system that
is installed during construction of habitat as it is an integral,
structural part of habitat, 2) is an insulated forced air duct
system which reinforces cementitious material, 3) reduces volume
weight of top beam, 4) requires no additional framing, etc., to
hide it, and 5) uses process of varying opening sizes custom
installed at site to regulate required air supply. Blocks and beams
can also be used with a standard sized hole becoming the air duct
with no other duct work required.
[0060] An advantage of the present invention is its ability to
emulate the aesthetic appeal of industry's standard habitats while
being composed of a completely different, unique cementitious
material. It is the invention's synergy that allows it to overcome
problems preventing AAC's acceptance by construction industry. Each
of the present embodiments is crucial to whole as it is
synergistic, i.e. without support beam system, roof panel system
would not feasible, and without invention screws and light-weight
roof waterproof coating system the support beam system would not be
feasible. AAC systems are environmentally friendly. In contrast,
conventional wood structures create a problem of waste, while this
system reduces waste to almost nothing. What waste there is can be
dealt with by the teachings hereof. It was discovered that the
waste hereof is to grind the AAC into powder and then, by
optionally adding proper nutrients and fertilizers, turn the
mixture into a yard enhancer so that no waste has to be removed
from the building site.
[0061] The manner by which the system hereof applies the processes,
machines, articles of manufacture and compositions of matter will
become apparent in the description which follows, particularly when
read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0062] FIG. 1 is an exploded perspective view of a partial, two a
story cementitious dwelling constructed in accordance with the
teachings of this invention, showing specifically a first floor
construction, with portions removed, a second floor with a partial
roof to override the first floor, and a partial roof section to
override the remainder of the first floor.
[0063] FIG. 2A is a partial perspective view of a wall, with a door
and a window opening, using in section, a base block and mini-wall
block combination, top block/beam and optional curved block wall,
showing architecturally finished coordinated seam system that
enables thin coatings previously considered insufficient.
[0064] FIG. 2B is a continuing partial perspective view of a wall,
with a door and a window opening, omitting base block and mini-wall
block and substituting them with a wall block and big base block
showing architecturally finished coordinated seam system revealing
a sloped and architecturally finished crown block on top.
[0065] FIG. 2C is a continuing partial perspective view of a wall,
using a second story on floor panels, with a door and a window
opening, substituting top block with top beam over openings and
omitting wall block and substituting full wall blocks, with
architectural features added after installment.
[0066] FIGS. 2BB-1 & 2 are two partial perspective views of
wall blocks that are routed with a vertical chase and shaped edges,
where FIG. 2BB-1 is an example of architectural design routed on
face by tools of invention.
[0067] FIG. 2CC is a partial perspective view of an elongated,
vertically oriented casing block, showing incorporated utility
chase and a curved insert to facilitate pulling/fishing electrical
wiring or cable through the blocks. It is adjoining a finished wall
block.
[0068] FIG. 2D is a partial perspective view of a top block which
dimensionally compliments wall block to allow precise height
dimension for doors and window openings, showing the invention's
casing and utility channel as well as industry standard slot for
reinforcing.
[0069] FIG. 2DD is top block beam that combines functions of a
header for openings and a bond beam for wall and can house utility
channel and invention's enclosed, insulated duct system.
[0070] FIG. 2E is a partial perspective crown block, having crown
molding, showing a tapered top wall with a longitudinal slot and
crown block used as floor support system.
[0071] FIG. 2F are two views, perspective and plan, showing a
special molded plastic insert to convert a utility chase into a
multi-chamber chase.
[0072] FIGS. 2G and 2H are several views illustrating curved AAC
blocks and manufacturing procedures, along with exemplary shapes
for said curved blocks.
[0073] FIGS. 2I and 2J are a series of views showing a preferred
manner of providing temperature transfer within an AAC
dwelling.
[0074] FIG. 2K is a view of inserts to form a temperature transfer
system.
[0075] FIGS. 3A through 3I are different views illustrating various
aspects of a roofing beam support system according to this
invention.
[0076] FIGS. 4A through 4D are different views illustrating various
aspects of this invention's water proofing system, and gutter/down
spout system, as applied to roof and invention's moisture removal
system.
[0077] FIGS. 4F through 4H are views illustrating the waste-free
roof panel system according to the present invention.
[0078] FIGS. 5A and 5B are two views showing further this
invention's panel bond beam system. invention's panel bond beam
system.
[0079] FIG. 5C is a cross sectional view of a wall detail showing
invention's panel bond beam in conjunction with invention's wall
block and top beam with duct system, routed with casing block
design for spanning opening.
[0080] FIG. 6 is a partial side view illustrating invention's
corbel bond beam system which allows floor and roof panels to be
secured directly to a cured cementitious mid wall sections.
[0081] FIGS. 7A through 7D are different views illustrating a
preferred auger screw, "R" screw for securing AAC materials
according to this invention.
[0082] FIG. 7AA is an exploded perspective view illustrating a
preferred hollow bar, a hybrid of a unique screw and flange bar
which replaces standard rebar, and selected tools used to cut,
crimp and create serrated ends in hollow bar.
[0083] FIGS. 7AAA through 7CCC are different views illustrating a
preferred flange bar, showing a modified rebar as used in fastening
and holding pieces in position until grout can be added.
[0084] FIGS. 7E and 7F illustrate fastening devices for installing
panels onto wood and steel roofs supports.
[0085] FIGS. 8A through 8D are various views illustrating a dual
functioning screw for attaching items to AAC materials.
[0086] FIGS. 9A through 9C are selected views of an AAC stair case
assembly.
[0087] FIG. 10 is a top view of an improved firewall with opening
and door.
[0088] FIGS. 11A through 11D are various views of routing tools,
such as a hand held utility chase cutting tool.
[0089] FIGS. 12A through 12C are various views of a tool for
inserting wires into utility channel and fastening in place.
[0090] FIGS. 13A through 13C are various views of a duct system for
manufacturing structures according to the invention hereof,
including architecturally finished seam system.
[0091] FIG. 14 is a perspective view of a pair of AAC crushing
rollers members for converting and transforming the AAC waste into
a suitable fertilizing base for trees, soil conditioner, and the
like.
[0092] FIG. 15 is a side view of a joint cleaner for removing and
smoothing excess grout from a seam.
[0093] FIG. 15A is a perspective view of the joint cleaner of FIG.
15.
[0094] FIG. 16 is a partial side view of a double edge cutting
blade for creating openings in AAC walls.
[0095] FIG. 16A is a perspective of a portable cutting tool using
the double cutting blade of FIG. 16.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0096] The present invention relates to a system for manufacturing
structures and habitats of cementitious materials, more
particularly by the use of an autoclaved aerated concrete. The
invention will now be described with regard to the several Figures,
where like reference numerals represent like components or features
throughout the various views. Though the invention has
applicability to a variety of cementitious materials, the further
description, for convenience, will be restricted to the use of
autoclaved aerated cementitious (AAC) materials. Turning now to the
several Figures, FIG. 1 is a perspective view of an AAC constructed
structure 10 according to the techniques of this invention, while
FIGS. 2A to 2C illustrate sections of structure wall blocks 200A
and 200B.
[0097] AAC blocks are typically formed by first preparing a slurry
of the AAC mixture and placing same into current industry standard,
large mold measuring approximately 4' wide by 24'' deep and 20'
long. After the slurry sets, the form may be lifted out of the tray
and cut into the desired sizes. Industry standard panels are always
steel reinforced and sized 2' wide by +/-8'' thick and when used
for walls are +8' long (for vertical height). Most blocks are
usually 8'' wide by 8'' tall.times.24'' long with only one USA
plant manufacturing a jumbo block of 2'.times.4'.times.8''.
[0098] The system hereof shows manufacturing modifications of
8''.times.16'' for top block, which is coordinated with wall block
of industry standard 2'.times.4' but new dimensional length of 82''
which requires modifying mold length by additional 6'', from the
prior art, so three lengths of 82'' wall block as well as
coordinated casing block can be manufactured without waste.
Accordingly, one preferred size is wall block 200B having an
elongated dimension of standard pre-hung doors with only jambs to
slip flush into invention's casing block system so that no
additional wood trim is required or customizing blocks at site.
Further, through the use of the large blocks 241, and the unique
and precise manufacturing techniques, it is now possible to
construct a habitat with the architecturally finished structural
components. That is, the blocks 12 have specifically located
architectural finish along the edges of faces that will be abutting
at joints of the blocks and hides the seams and surface deflection.
This eliminates the need for extra surface finish, wood molding,
other material or labor. The finish need only be a paint or a
superficial layer of smooth stucco, as known in the art.
[0099] As illustrated in FIGS. 1 and 2A, the system hereof is
amenable to the use of curved wall sections 205. FIGS. 2G and 2H
illustrate techniques for manufacturing the curved wall sections
205. That is, alternative curved blocks 205 are manufactured by
wires, as known in the industry, but modified by being connected to
a computerized, mechanical arm which cuts AAC as pattern and arrows
as illustrated. There are presently no curved blocks being
manufactured anywhere in the world to the knowledge of
Applicant.
[0100] For more frigid climate construction applications, reference
is made to FIGS. 2I and 2J, showing the invention's temperature
transfer system. The manufacturing of transfer channels 54 is
unique in that the tubes 251 inserted into the pan mold 250 are two
conical tubes with threaded ends 255, one male and one female,
which after curing are separated by tool 253 which is inserted into
larger end and engages indentations 252 and is twisted to unscrew
tubes. Optional flange 254 on female conical tube holds it
stationary while male tube is first unscrewed and withdrawn. The
purpose for tool and conical shape is ability to ease withdrawing
longer sections of pipe from cementitious material, as tool employs
fulcrum to initially break tube free and then conical shape allows
for no resistance as withdrawn. This now allows for extremely long
voids/channels to be easily created. Also ends the need for coring
of individual blocks as is currently done since blocks cut with
void suffice.
[0101] The temperature transfer system of this invention allows for
excess heat, usually wasted and/or lost, to be realized and
circulated 58 via air channels 54 throughout exterior walls 200A
and panels 40 of habitat. System can employ a geothermal 56 and
solar 55 storage tank 52.
[0102] After the cementitious materials are prepared, construction
can begin. Initially a superior concrete foundation, or footer with
slab is poured, as known in the art, to present a base for
receiving the AAC blocks. The blue prints, as known in the art, are
measured and laid out on floor by a qualified individual. Correct
designations are marked on floor for openings, block type, location
of outlets, etc. From this point a small crews of four unskilled
workers using a level, trowel and drill can construct a quality
habitat in half the time of a comparable "stick built."
[0103] A first step in constructing invention is the wall system,
FIGS. 2A through 2C. The process comprises selecting a
discontinuous first course of elongated AAC base blocks (FIG. 2A)
for placement on a pre-built foundation. A base block 201 is one
solid structural finished component that is load bearing, utility
receiving, architecturally finished and uniquely dimensionally
processed. The respective +/-10'' tall.times.+/-9'' wide blocks are
oriented with a longitudinal slot, called a utility channel 202,
see also FIG. 2I, exposed along the upper surfaces or/and along the
vertical face thereof, into which utilities 217, 216, 123, 124 are
inserted and later covered by subsequent course and/or preformed,
dimensional type of cementitious board 229 which fits perfectly
between notch 225 at the base and start of architectural finish 208
so that there is no seam and it becomes integral part of
design.
[0104] Alternatively, the base block 201 may be omitted and the
mini-wall blocks 200A substituted with wall blocks 200B, see FIG.
2B. Wall blocks have a custom notch design near base 202 (FIG. 5B)
that is covered by flooring and/or optional baseboard. Another
alternative (FIG. 2C) may be the omission of casing blocks and
instead, wall blocks 200B are architecturally routed, including
utility chase. All blocks work with the present invention's utility
channel system.
[0105] Whatever block process is used, the blocks are cemented into
place and leveled, except where door openings 212 are located.
Initial leveling is critical as all subsequent courses of blocks
can be laid directly on the base course without further delay as
subsequent leveling since AAC blocks are dimensionally
accurate.
[0106] Continuing description using base block 201, as apparent,
the purpose of the slot, as best seen in FIG. 5A, is to receive
utilities, i.e. electrical wiring. After utilities and all inserts,
etc. are placed in the utility channel 202, then a thin cover
composed of plastic or paper may be placed over utility channel 202
opening to prevent special AAC mortar 19 from falling into utility
channel 202 when constructing subsequent blocks and panels, as
mortar would obstruct future installments of utilities which can be
pulled/fished. Additional utilities can be placed on top of the
base block 202 which are accepted into the utility channel 202 in
base of second course 200. The base blocks 201 are +/-10'' high and
+/-1'' wider than mini-wall blocks 200A and have architectural base
board finish 208 which recesses and reduces base block to width of
subsequent mini-wall block 200A. The base block 201 also has
optional variably sized recessed notch 225 at base for overlapping
the flooring. Reference numerals 208 & 225 create the
invention's unique attribute of being architecturally and
functionally equivalent to a baseboard; so even while housing
utilities, it is structural and functional as well as having
ornamental finish.
[0107] Outlets 216 may be located into the base block 201 by
cutting opening using special rotor plunging tool and template
guide. Outlet boxes, etc., fit exactly into opening formed by
template guide and are fastened into place, preferably using a
proprietary nail screw as illustrated in FIGS. 8A through 8D.
[0108] Thereafter, a method of vertically orienting and cementing
comparably designed, plural mini-wall blocks 200A onto at least
certain of the first course of blocks, where the height of each
block is a multiple of a nominal dimension of "X", where a typical
miniwall block is 6', and "X" equals 2'. Mini-wall blocks 200A are
preferably 72'' high, do not require wire reinforcing as does
standard wall panels that have manufacturing difficulties and
additional costs, but have advantages of panels in quick
installation and can be routed, see FIGS. 2BB-1 & 2BB-2.
Mini-wall blocks 200A can have utility chase system 202 integrated
into ends and sides to form horizontal and vertical utility
channels.
[0109] Alternatively to mini-wall blocks mounted on base blocks is
a method of employing wall blocks 200B, FIGS. 2A & B. Wall
blocks are +/-6'-10'' tall so top equals height of standard door
with frame. Wall blocks which have hidden utility channel machined
into bottom, FIG. 5C. Additionally, specially designed tools are
able to architecturally finish wall blocks 200B with casing design
and utility channel allowing for omission of casing blocks.
[0110] In any case, thereafter, plural elongated casing blocks 203,
FIG. 2CC, preferably the height of wall blocks, are vertically
oriented around the first horizontal course where openings 212 for
doors and windows are to be placed. Invention's casing blocks 203,
FIG. 2CC, are used for window and door openings and are structural,
integral components of wall which have architectural finish 208 and
can have a utility channel 202. Electrical switch boxes 216 can be
located in casing blocks 203 at door openings and are constructed
similarly to outlet boxes 203 in base blocks. The slots for the
utility channel are of such a width that when windows and doors are
installed their frames conceal slots and only caulk or shoe mold is
required to finish. The top beam has casing block's architectural
finish where openings are located.
[0111] Casing blocks have vertical and horizontal "X" factors.
Vertically, the same dimensional vertical "X" equals wall blocks
200A & 200B, so their top heights are level. This level height
is optimized at +/-6'-10'' to match rough opening for doors and
windows. Horizontally, casing blocks are "X" equals 2' or 1', so
that either 17+/-'' wide for full size openings (ex: 36'' (3'-0''
door)+2+/-'' (3/4''+3/4'' frames & gap), +34''+/-(two 17''
Casing Blocks)=1' center), or 14'' for half size openings (ex: 30''
(2'-6'' door)+2+/-'' (3/4''+3/4'' frames & gap), +28''+/- (two
14'' Casing Blocks)=1' center). The walls are constructed on 1'
centers with minimal waste. By disciplining design using matching
units a wall can be constructed without having to cut 2' wide wall
blocks. Doors and windows with 3/4'' jambs can slide under
subsequent course and into opening, requiring nothing else to flush
finish other than trim or caulk, as the architectural finish 208 on
blocks blend into door and window frames and become one
architectural unit when painted. Conventional finishes have
architectural finish added onto wall and so protrude away from
wall, while present invention has finish recessing into structural
walls as walls are thick enough to use the invention's time and
material saving process.
[0112] A simplified wall process is for the tools, see FIGS. 11A
through 11D, hereof to architecturally finish 243 wall blocks FIG.
2C, at openings and create utility channel 202 so that a casing
block is not required, as wall block has features of casing block
machined into it. The width of opening is flexible so that only top
block/beam 206 acting as header spans or big base block 241, see
FIG. 2B, used under window are cut to fit. Big base blocks 241 are
basically wall blocks turned horizontally so all window openings
can have standard height from floor of 24'' and variable width.
This is preferred method of all options.
[0113] Where the utility channel 202 intersects with other blocks
or changes angles, in a preferred embodiment, a curved insert 214,
FIG. 2A, sized to be slidably placed into the longitudinal slots
202, may be placed into perpendicularly converging utility slots to
provide a continuous curved path for easy wiring of the erected
structure in future after direct access is closed off. By this
arrangement, and with pre-positioned openings extending to the
inside from the longitudinal slots, the entire structure may be
suitably wired with recessed utility boxes to present a wall
surface suitable for finishing.
[0114] Where architectural finishes 208 for casing blocks 203 and
top block/beam 206B meet, an architectural insert 213 is placed to
cover incompatible intersection, see FIG. 2B.
[0115] Top block beams 206, FIG. 2D, are placed as a horizontally
oriented course of comparably designed AAC blocks, where the
longitudinal slots 202 over the openings, such as doors and window
openings, and casing finish 208 are exposed downwardly toward the
opening. An optional architectural finish 208 can give a crown
molding appearance to top block where floor panel 59, FIG. 5A, will
rest on top block 206. Top block are preferably manufactured as
beams and have enclosed air duct system and reinforcing channel
that coordinates with roofs beam system.
[0116] Thereafter, the top most course of wall, comprised of
invention's +/-16'' top block beam 206, is placed on wall blocks
200A, 200B, not 200C, and/or casing blocks 203. Top block can have
variation of architectural finish 208 as casing blocks for windows
and doors, as well as continuous design to equal crown molding,
which allows for one structural component, top block, to replace
four standard pieces: header, filler, casing and crown.
Additionally, top block is of specific dimension so that base
block, mini-wall block and top block form a minimum 8' high wall. A
unique feature of this invention is the provision of an effective
method to construct a dwelling using primarily precut and sized
blocks of cementitious material. By the use of such cementitious
blocks containing specific dimensions unique to this invention
process and not in prior art, an 8' high wall can be constructed
using only two blocks (or three if using base block) which blocks
have specific, unique design and functions beyond just dimensional
advantage. Blocks are additionally modified with predetermined
slots and openings termed utility chase system for utilities, i.e.
electrical wiring, plumbing, etc., facilitating construction of
habitat.
[0117] Further, also employing tools for finished architectural
routing for either the base block, casing, features for openings,
and/or crown block, smooth finished walls are transformed into
architectural finished walls with no additional materials.
[0118] For rounded walls and/or corners, if desired, one may employ
arch shaped rounded blocks 205, where the rounded shapes of such
blocks may be accomplished by inserting rounded mold (FIG. 2G) into
an industry standard AAC pan. Alternatively, a computerized
mechanical arm may run wires through cementitious material (FIGS.
2H) in a unique pattern producing curved blocks with very little
waste, and which waste is able to be recycled as it is still in
green stage before autoclaving. This finishes wall construction
processes.
[0119] The corbel bond beam system (FIG. 6A) is the system's
approach to attach floor and roof panels directly into the mid wall
section surface instead of on top of walls that requires a great
deal more construction effort and material. The corbel slot is
formed at manufacturing or on-site field routed using the
proprietary tools according to this invention, see FIG. 11A, with
different bit. The corbel bond beam 60, which is reinforced with
rebar 35, is set into the slot with mortar and fastened with the
proprietary screw 70, note FIGS. 7A through 7AAA, or the
invention's alternatives, which engage rebar reinforcing.
[0120] When there are multiple floors, floor panels can be placed
directly on top of first level wall top block/beam (FIG. 5A) with
panel end flush to exterior wall. Floor panels, according to this
invention, may use invention's bond beam slot 50 and proprietary
auger screws 70 to effectively replace several steps of prior
methodology. In prior art systems, a bond beam was to first drill
vertical holes into top of wall, then short sections of rebar were
mortared into holes, and thereafter a long, horizontal rebar was
tied off to vertical rebar. This necessitated a space between end
of floor panel and a block placed flush to exterior face of wall.
The bond beam was formed in the gap between panel end and wall
block using rebar and mortar. This method required additional
material, labor and days of curing time before subsequent floors
could be constructed. The present invention eliminates several
steps and materials and allows construction to continue
uninterrupted.
[0121] Floor panels 59, see FIG. 5B, hereof have unique bond beam
slot 50 achieved by manufacturing AAC similarly to roof panels for
a proprietary gutter system, see FIGS. 4A through 4D, where upper
course(s) of steel reinforcing 52 stops short of panel end than
other layers so slot can be routed and bit not hit reinforcing
steel. Rebar 35 is horizontally laid in bond beam slot 50 and tied
to screws 70 and then bond beam slot is filled with mortar 19 as
base block 201, which is the first course of next wall, is
laid.
[0122] An alternative floor support system is illustrated in FIG.
5B for a crown block 207B to be placed into wall during
construction to support floor system. This invention's method
allows for wall construction to continue until all walls are
constructed before floors and roof panels are installed. When floor
panels are installed, the gap between end of floor panel and wall
is filled halfway with rebar 35 and mortar 19 and becomes bond
beam. The upper half of gap is left a void and becomes a utility
channel 202 for wires 217 and other utilities to be inserted.
Outlets 216 are placed in floor panel using invention's method in
area void of reinforcing. Finish floor covers uniquely located
utility channel or small gap that can be filled with additional
mortar.
[0123] Where stairs are employed to travel between floors, the
invention's stair system is employed as shown in FIGS. 9A through
9C which are partial views of stairs made entirely of AAC. There is
no prior art of cementitious stairs being supported only at ends
and reinforced by adjoining steps. All prior art uses either steel
reinforcing throughout or supports in middle of stair, which
extends to ground along total run of stairs.
[0124] The invention's stair system uses cementitious blocks 90
which have an angled slot 91 that corresponds to the desired pitch
of the stairs. The angle support brackets 92 are secured to the
wall at the desired pitch of stairs, which pitch corresponds to
slot 91 in cementitious block. Blocks are simply slipped onto
support bracket at top of stairs in gap, see FIG. 9B, reference
numeral 93, between brace and floor and then slid down and mortar
19 to secure onto top of previous block. Optionally, a screw 70 can
be used for additional fastening. The angle iron 92 with special
slot 91 makes a permanent structural unit. Mortar placed on ends of
stairs additionally bonds stairs to AAC walls. Face of cementitious
AAC blocks can be routed to have a tread 94 and/or other
architectural advantages. The advantages allow for additional
safety of fire proof stairs cases which are devoid of
squeaking.
[0125] Thereafter, if there is not to be an additional floor, on
the top most course of wall comprised of top block, a crown block
207, FIG. 2A, featuring a sloped top wall 228 is cemented to the
top course. The slope is comparable to the roof slope so that the
roof panels may be supported thereon and secured by suitable
fastening means. FIG. 4B further shows a tapered crown block 207
secured to the top of the wall for mounting a roof panel (40) and
roof support members. The crown block has a slope equal to the roof
panel pitch and is manufactured by taking a standard base block
width and cutting in half so that mirror sides equal slope pitch of
roof. The interior face is routed to resemble crown molding. The
result of this inventive technique is a single structural piece of
cementitious material that has architectural attributes of finished
wood trim and is used to bond pitched roof panels to flat walls.
Crown blocks with a level top, instead of angled to the roof pitch,
can also be used to add height and design features to any wall.
[0126] The roof is constructed by first securing AAC roof panels 40
to the roof support beam system, beams 30, 31, 32, where a typical
roof has a plurality of beams arranged in specific load and stress
managing pattern.
[0127] The construction method may be continued by positioning the
invention's support beam system, see FIGS. 3A-3F, on walls. The
cementitious beams are comprised solely of cementitious material
with steel reinforcing, and optionally can have invention's
reinforcing channel 36, see FIG. 3F. Support beams require only
mortar and fasteners as unique interlocking design, FIGS. 3C &
3D, eliminates need for interlocking brackets, bolts, or other
mechanisms. All types of roof pitches and designs, including hip
and valley, FIG. 3A, are now possible for a purely cementitious
roof and support system.
[0128] The supporting beam system with reinforcing channel 36 is
constructed by placing rebar into channel (and utilities), tying
all rebar together, which can include rebar coming from
foundation/slab, then drilling holes into beam and pouring mortar
into beams 38, FIG. 3F, so that incredibly strong support beams
result. The invention allows for AAC surrounding hard concrete
reinforcing channels to receive fasteners 70 and so secure roof
panels to supporting beam system. Invention's roof system requires
no brackets, braces, bolts, etc., as does all prior art. At most
what may be required are tension tie rods for certain hip roof
designs to give walls extra support.
[0129] The construction process is continued by placing roof panels
40, see FIGS. 3E and 3F, on supporting beam system. When a roof is
resting on standard 8' wall instead of a second floor FIG. 4B, then
a fourth level of blocks comprised of crown block 207 can be used.
As best seen in FIG. 4B, a series of crown blocks 207, preferably
eight (8) inches in height, are cemented to the planar surface 229,
where the crown block 207 features a slanted upper surface 228 for
receiving an angled roof panel 40. The panel 40 may be secured to
the crown block 207 by invention screws 70, as shown in FIG. 7A,
and mortar 19 as known in the art, on planner surface. Crown
blocks, FIG. 2E, can also be structural for openings with cavity
227 being filled with rebar and cement.
[0130] The beam system utilizes the invention's optional
reinforcing channels 36, FIG. 3F, which can be used in addition to
standard reinforcing to facilitate easy construction and provides
even stronger support due to internal bond beam/utility channel
tying together the entire habitat. Beams can have a squared edge
corrugated pipe 36 inserted into the AAC mold during manufacturing.
The AAC fits between the square corrugation in pipe and holds fast
and is strong enough to remain intact during initial construction.
The hollow corrugated pipe (36) at site has rebar 35 placed inside,
as well as any utility conduits 26 desired, which conduits can be
accessed for lights, etc.
[0131] Roof beams are erected and fastened so that the hollow core
formed by corrugated pipe, which is termed reinforcing channel 36,
align each other at intersection/joint of beams. After beams are
joined together and set with proprietary screws 70, the AAC mortar
is pumped throughout the reinforcing channel system 36 resulting in
an incredibly strong beam system that ties the entire structure
together. This reinforcing channel system also allows invention
screws to fasten roof panels into the softer AAC portion of the
beam. Optionally, FIG. 3H, a standard concrete beam 19 can be
constructed and then an AAC beam 30 adhered with mortar to top of
concrete beam so result is a dual material beam which has softer
cement for fasteners on top and harder, reinforced concrete on
bottom. The concrete beams can be constructed and poured at site
with foundations.
[0132] While any type of pipe can make reinforcing channel, the
reasons for using optional corrugated pipe or corrugated, helical
conical mold insert 255 (FIG. 2K) which unscrews from mold, are: 1)
the corrugation gives extra surface strength and adds additional
strength to reinforcing channel when filled with concrete as two
cementitious materials bind against each other; 2) the corrugation
prevents AAC outside and cement inside from separating from pipe
during stress flexing; and 3) the corrugated pipe allows mortar to
flow throughout entire system as AAC is known to absorb moisture so
quickly that if system had only exposed AAC the mortar may quickly
adhere to channel walls, possibly clogging channel and thus prevent
mortar from reinforcing certain areas.
[0133] The roof panel system is then fastened to the beam system.
The teaching of the present invention's waste-free system is
illustrated, in part, in FIG. 4E. This simplifies construction by
manufacturing a standard length precast cementitious panel for the
entire roof system. Once the length is determined, the parts (A),
(B), (C), and (D) are simply cut off site and delivered and
installed in a manner which emulates contemporary roof lines
without waste. The cut angles of 30.degree. and 60.degree. (FIG.
4G) are turned to meet each other, i.e. (A) to (A) through (D) to
(D). When laid at a 45.degree. angle incline, FIG. 4H, or as known
in the art " 12/12" pitch, and installed on the invention's
teachings of the beam system, FIG. 3A, it creates a perfectly
mirrored hip or valley, FIG. 14F. The roof layout, FIG. 4E, becomes
simplified and cost effective with zero-waste. Also, what is lost
as just uninhabitable attic space under typical roof constructions
becomes finished living area, FIG. 4H, by the teachings of this
invention.
[0134] The roof panel system is then fastened to the beam system
and roof panels waterproofed. The roof design is identical for both
sections A and B of invention's roof waterproofing system (FIG.
4A). Section A is a perspective of a finished stage using a
different water proofing material 47 than Section B's segment which
is shown at an initial stage in its construction using the
technology hereof. It is important to note that the invention's
water proofing system for roof panels is of four distinct
processes/features, namely: 1) water proof coating 47 &/or 41;
2) the facia water deflection system 45; 3) integrated gutter
system 44; and, 4) gutter box 48 which replaces down spouts. The
gutter box 48 comprises a generally rectangular housing portion 61,
see FIG. 4D, having at least one wall opening 62 for receiving
water overflow from the angled gutter slot 63, a tapered lower wall
64, and a pair of outer walls 65 that feature water outflow slots
66 at the bottom of said outer walls 65, note the water flow
arrows. The roofs water proofing system is constructed as
follows:
[0135] FIG. 4A, section A, 47 is a composition of matter for a
roofing material, having the following characteristics: waterproof,
climate durable, chemical resistant, vapor permeable ("breathes",)
high modulus of elasticity (stretchable), durable (10+ year use
expectancy), can be continuously re-coated so no waste material has
to go to landfills, can be tinted for various colors, and bonds
well to AAC. It is simply applied by spray or roller.
[0136] FIG. 4A, section B, as a preferred system, incorporates a
polyester/nylon mesh 42, having alternate sections of a tight mesh
43 and a loose mesh, and is placed over the AAC panels in the
direction of the ridge down to the eaves. Next, an elastomeric
composition 41 is applied to the mesh, and, as a result of the
porosity of the loose mesh, the elastomeric composition goes
through the loose mesh and adheres to the AAC panels. However, the
elastomeric material will not go through the tight mesh 43 such
that an air channel 47 is created between the tight mesh 43 and the
AAC panels 40. Further, another coat of the elastomeric material 41
may be applied for extra wear resistance. The respective air
channels 47 allow moisture in the AAC panels to escape, i.e.
breathe. Additionally, the air channels 47 also function as air is
drawn up through the channels from the eaves end of roof to the top
ridge vent 48 by use of naturally occurring temperature and wind
where it may be vented 48 to the atmosphere.
[0137] The integrated gutter system of this invention uses industry
standard AAC roof panels with a modification in steel reinforcing.
Since gutters (FIGS. 4A and 4B) 44, may be routed out of the roof
panel 40, the top rows of embedded reinforcing rods 52, see FIG.
4B, extend short of the edge similar to bond beam panels (FIG. 5B).
There is no need for all the structural reinforcing at the gutter
location as AAC is strong enough by itself An angled routed groove
44 may be added to the AAC panels to transmit moisture out of the
roof assembly and act as an integrated gutter system to gutter box
46 hereof. No prior art of cementitious materials with integrated
gutter systems employ a gravity driven water removal method. All
prior art relies on inferior water pressure method as subsequent
water forces previous water toward down spout box and off the roof.
The prior art's use of water pressure has negative results of
residual moisture remaining in trough which eventually causes water
damage due to debris build up and/or freezing. Invention's down
spout box 46, FIG. 4D, disperses moisture out and away from habitat
by curved wall and wide slot at base. The interior ridges and
various platform heights of curved wall near slot break up the mass
of water into smaller droplets so as it is propelled out of box
large volumes of water do not overburden any one area too much.
[0138] Finally, the facia water deflection system 45 is one and the
same material as the roofing and is one continuous niece of roofing
material, specifically shaped to have reversing angles with a
series of sharp angles so it is impossible for water coming off the
roof to run down its face, but rather gravity pulls water off its
face at several different places, which not only deflects water
away from house but also breaks water down into smaller droplets so
it does not damage landscaping beneath. Therefore, facia design is
not just a cosmetic architectural feature, it is an unique
functioning aspect of the roofs waterproofing and moisture removal
system much different than existing plumb facia boards and molding
which recess with angles but not reversing angles. An integral
functioning process advantage of the finished ends of the roof
panels lies in its water deflection that is multifaceted. The
reversed angle routed end makes it impossible for excess moisture
from the roof to run down face of the panel end/roof facia. This
overcomes two failures of the prior art, namely: 1) moisture
carrying naturally occurring debris running down vertical facia
causes unsightly streaks; and 2) moisture running down facia is
easily blown back toward habitat. By means of the instant
invention, the need for additional labor and material of drip edge
is avoided, while adding unique architectural enhancement to the
habitat.
[0139] Therefore, the present invention's roof panel design and
process of moisture removal system is comprised of a single
cementitious material identical to the roof and is actually roof
material itself and thus an indivisible component of roof
consisting of two distinct components: 1) a downwardly angled
trough 44 which feeds moisture to a down spout or the down spout
box of this invention; and 2) a facia 45 with square edges and
upward, reverse angle pitches having a multi faced formed edge of
cementitious roof. This roof system is then coated with either of
the two water-proofing materials 47, or 41. Both moisture removal
attributes are part of the present invention's roofing system and
work in conjunction with each other as one moisture removal
system.
[0140] Doors are possible with AAC, as seen in FIG. 10, so that
even four hour rated fire wall 204 may be possible with an
operating door 100 which is composed of AAC. The door face can have
all types of architectural or decorative effects as a standard wood
door. The wall is composed of standard wall blocks 200A, 200B but
uses casing blocks 203 having custom fire thwarting design and
latch system 101. The door can be held in place by special heat
resistant piano type hinge 103 or the internal hinge 104 hereof,
which has special sliding hinge pin so all mechanical parts are
protected within fire proof AAC.
[0141] Now that the individual embodiments of materials and
structure of habitat are understood, what needs to be explained is
the preferred fasteners and tools of this inventive system. The
auger screw (FIGS. 7-7C) is a preferred method of securing, not
just to fasten, but to actually bond AAC together. The screw 70
acts as an auger screw and gets its name from the fact it provides
more structural advantages than standard rebar but does so with the
ease of a screw, especially as screw engages any steel reinforcing
in the panels and elsewhere. As noted above, a fastener 70 can be
used to secure a roof beam 30 and/or panel 40 to the crown block
207.
[0142] One difficulty is that prior art fasteners, such as the
Helifix, can work free over time without mortar holding pieces
fast, consequently if mortar in joints ever failed then system is
in jeopardy. Also, the Helifix is inadequate in size to secure
large, heavy pieces of cementitious material, and due to need for
cement to assist bonding, simply increasing size does not solve its
design inadequacies. To improve the fastening capabilities of AAC
materials, such as the roof beam to the crown block, a new and
unique fastener had to be developed.
[0143] Though different, U.S. Pat. No. 5,143,498, to Wiftman, and
granted Sep. 1, 1992, teaches a rubber roofing material fastening
device that includes an optional liquid sealer to facilitate the
process of affixing roof items to the upper surface of a roof The
fastening device has a longitudinally extending centrally located
chamber that is coaxially aligned with the longitudinal central
axis of the fastening device. The chamber has a plurality of
laterally disposed openings that extend from the chamber to the
outer surface of the fastening device. The chamber is adapted to
receive a liquid sealant at an opening in the upper surface and
disperse same through such lateral openings. The exterior surface
of the screw shaft is formed with screw threads having a dual set
of helically wound, threaded members. The external, most radially
outer portions of the threads are grooved with serrated teeth to
enhance the holding power of the fastening device.
[0144] The screw fastener member 70, FIGS. 7-7C, of this invention
is comprised of a solid core 71, preferably "hour glass" in shape,
within an annular wall 72 to define three elongated cavities, one
passing through the center to each side, and two opposite each
other on outer sides separated by the center cavity. The three
elongated cavities create two functioning processes with the two
cavities opposite each other performing the same process, namely,
the center cavity is a mortar chamber 73 and the side cavities are
dust chambers 74. Along the annular wall there are provided plural
openings 75 in communication with the mortar chambers.
Additionally, there are provided plural openings on the annular
wall and in pointed end 78 in communication with the dust chambers
with at least one cut-out window having a scraper blade 76, which
is a portion of the cut-out of the wall extending tangentially from
the annular wall 72. In operation, the dust chambers 74 captures
AAC dust created by scraper 76, as well as through opening in
pointed end 78. The scrapers 76 serve two functions: 1) to enlarge
hole area around shaft 72 so that an air space is created between
the AAC and shaft 72, which space will be filled with mortar
flowing out of mortar chamber 73 via opening 75; and, 2) remove
from the enlarged hole all lose AAC dust so that mortar flowing out
of mortar chamber 73 has a good surface for bonding. The head
portion 77 removably receiving a square head power screw driver as
an air ratchet, which square opening is an opening through to the
mortar chamber and through which mortar is poured into cavity after
driver bit has placed screw member 70.
[0145] Additionally, at head 77 is the termination of helical
thread arrangement 79 at an open slot 77A so that the entire screw
can be counter sunk into AAC. Finally, exterior of the shank 72,
from the head portion 77 to the opening, is pointed at one end 78,
and includes said large angled helical screw arrangement 79 with
wide threads. It will be seen that this is in sharp contrast to the
very shallow angle and narrowness of the helical threads of a
conventional screw. The design of thread of this invention is
unique to its application for maximum hold with least negative
torque influence thereon, and damage to the AAC. The result of the
invention is a screw which has all the advantages, and more, of
rebar but can be installed in one easy step directly through
numerous pieces of AAC and secures in place each piece of AAC,
regardless of where AAC is located, i.e., slope, angle, etc. which
before this invention was not possible.
[0146] Alternative fastening inventions are the hollow bar (FIG.
7AA) and flange bar (FIG. 7AAA). The hollow bar has a dust chamber
74 within annular wall 72 with advantage of provided plural cut-out
windows having a scraper blade 76, which is a portion of the
cut-out of the wall extending tangentially from the annular wall
72. In operation, the dust chambers 74 captures AAC dust created by
scraper 76, as well as through opening in pointed end 78. The
scrapers 76 serve two functions: 1) to enlarge hole area around
shaft 72 so that an air space is created between the AAC and shaft
72, which space will be filled with mortar being poured into gap
around exterior of shaft at entrance to hole; and, 2) remove from
the enlarged hole all lose AAC dust so that mortar has a good
surface for bonding. The design of thread of this invention is
unique to its application for maximum hold with least negative
torque influence thereon, and damage to the AAC and the gaps 705 in
thread are for purpose of allowing mortar poured into opening
created by flanges to flow continuously down between screw wall and
AAC and around threads sections. The result of the invention is a
screw which has all the advantages, and more, of "R" screw, but can
be manufactured for less cost and be custom cut at site to variable
lengths as thread gap 705 and opening pattern repeats itself.
[0147] The crimping tool for cutting and forming hollow bar has
multiple blades which form functions of: 1) crimping tube which
helps hollow bar enter AAC and grind it, 2) cut it, and 3) form
teeth out of cut end for two functions: 3A) on end entering AAC,
teeth cut and grind up AAC 706 and feed AAC dust up into dust
chamber 74, and, 3B) end used for driving hollow bar into AAC works
as would a normal head on a screw would, as it designed to receive
a drill bit and teeth have gaps which can receive a Phillips head
screw driver bit and allow hollow bar to be counter sunk.
Alternately, the bit fits over the end and tightens onto the
tube.
[0148] The flange bar is similar to industry rebar except invention
is modified by unique flanges 701 which are positioned and angled
705 to act like screw threads and design of being wider 704 and
thicker 703 at bar and then narrowing with receding leading edge
704 and getting thinner towards end 703 provides service of keeping
bar centered in hole by resistance of flanges against wall as it is
inserted and as flanges bite into walls they bind cementitious
pieces together and prevent shifting and/or movement while mortar
is added around bar it sets up. It has advantages of inexpensive to
manufacture and length being custom cut from long bar on site, but
has disadvantage of it requiring pre drilling a hole. The fastener
75, FIG. 7E, is a screw for installing AAC panels onto a wood or
steel rafter system, where the fastener features a pair of
concentric shaft portions, with the upper portion having broad
helical threads, and lower portion with much smaller helical
threads. It has the advantage of using these multipurpose threads
which are designed for surface area contact, where the tight or
lower threads 725 serve the purpose of starting the fastener into
the AAC and then properly imbedding into the wood or steel rafters,
FIG. 7F. The upper or loose threads 79 properly hold the AAC
without stripping or damaging the AAC, as well as to prevent the
fastener from going too far into the AAC, as the axial length of
the threads 79 correspond to the thickness of the AAC panels 40.
The fastener has features of AAC gougers 77B and countersink head
77A, that facilitates environmentally friendly one coat coverage of
roofing material 47, as taught by the present invention, and
replaces conventional heavy roofing shingles, etc., to make this
invention possible and practical.
[0149] Another fastening device, the nail screw 80, shown in
partial views in FIGS. 8-8D, has particular utility in securing
smaller items to a cementitious material, such as AAC. It can be
comprised of a strong, hard plastic instead of steel. It is unique
by its ability to be driven into the AAC with a hammer, while
further having the ability to be withdrawn by means of a rotational
hand tool, i.e., hand or powered screw driver 81 (FIG. 8C). This
device overcomes problems of prior art in that it will not easily
work free over time and yet is removable using the correct tool
without damage the item to be secured and/or AAC. The fastener
member 80 hereof is comprised of a triangular threaded 82 elongated
shank 82, with very low number of revolutions around shank and is
pointed at one end 85. The pointed end has openings 83 that aid the
"N" screw to grip AAC by gathering and compacting AAC dust that
presses against AAC wall. The "N" screw is topped at the opposite
end by a head portion, where the head portion includes prongs 84
for piercing AAC to provide additional holding of the screw member
80 in place. On the top side of head is a slot 81 for removably
receiving a screw driver head, as known in the art, to remove the
screw 80 from location. The design allows for unique multiple
applications in the same location that no other fastener with such
simple construction provides in AAC. Additionally, the elongated
shank can be hollow 85 and a standard finish nail 86 be driven
through which explodes the tip 87 and further anchors hammer nail.
To remove the hammer nail, one first applies a needle nose pliers
to remove the finish set nail 86 and then a screw driver and the
screw's threads supply enough torque for AAC wall to force exploded
tip to re-close and remove screw 80 from the AAC.
[0150] Turning further to the tools of FIGS. 11-11E, a table 90
(FIG. 11A) is of a block and panel architectural fabricator. The
table 90 has router bits 110, 111, 112 with the potential for
variable positions, and ability for different bits 110, 112 on each
router cutting simultaneously so each side of block, panel and/or
beam has desired architectural features, including utility chase
111 as an example in FIG. 11C, reference numerals 201, 203 and
beams 30, 31, 32. FIG. 11D is a partial view of a hand held version
cutting a casing block 203. The most unique aspect of the tools
hereof is the ability through combined use of the tools and
template system of FIG. 16 to fabricate finished openings for
windows and doors in a solid AAC wall.
[0151] A tool used for cutting utility chases into erected walls is
illustrated in FIG. 11A, which is a partial top view of a hand held
utility chase cutter 192 with the bit 120 which simultaneously cuts
a notch (FIG. 2BB) for sheetrock 209 and the chase 203. It uses the
template guide system 160, 163 hereof (FIG. 11A) as does most of
the hand held cutting tools. FIG. 11A shows utility chase 202 with
sheetrock 209 installed using screws 80, covering water supply 123
and waste pipes 124. The utility chase cutter can be used for
vertical as well as horizontal runs. Since the bit protrudes beyond
the face of the interior wall, it is able to cut down behind the
base block and up behind the crown block. Then a standard drill can
cut holes for utilities through floor panel. The chase is covered
using a single cut to size a piece of sheetrock. The tools hereof
have the capabilities of special dust collecting systems.
[0152] There is very limited waste product of AAC according to the
preferred practice of this invention, but what waste there is can
be easily handled by systems known in the art. Such systems can
crush waste cementitious pieces into dust, so they do not have to
be taken to landfills, which means habitats manufactured by the
instant invention can be constructed with little or no waste AAC
from the site having to go to a landfill, thereby lessening
construction costs and providing an environmentally friendly
practice. The resulting dust may then be used as fertilizer for
grass, etc.
[0153] As blocks of AAC are set in place, excess mortar can be
forced out beyond the wall face. To solve this problem FIG. 15
shows a partial perspective of present invention joint finisher
150. The joint finisher has a unique roller 152 which serves
several useful function namely, keeps blade 151 at optimal angle
for removing excess AAC mortar from block face at joints and roller
smoothes out any residual trace amounts of mortar, and the spring
pressured cleaning blade 153 removes AAC which may accumulate on
the roller, so that now one movement replaces prior art's several
tools and motions.
[0154] The hand held finishing tool shown (FIG. 11D) and may be
used with a template guide so that an architecturally finished
opening results where there was once just a wall. The window is
simply slipped in and caulked and/or finish nailed. No additional
wood trim or casing is required. The outlet and switch openings,
beam notches, etc. require a different type of template guide
having prongs. The guiding arms may be kept perpendicular by level
bubble on support arm 160. In difficult positions, such as a corner
notch, an angled template guide is used and, as the rotor zip type
tool goes around a guide, a chunk of AAC is removed which allows
the beam to seat into wall and be finished with mortar and
screw.
[0155] For easing an electrician's job of installing electrical
wire (FIG. 12A) into a utility channel, the wire inserting tool 170
has a long, specifically angled bar 170 with ability to slip into
utility channel 202 and wheel 175 enables installer to simply walk
along while the wire feeding wheel 171 by design aligns and lifts
wire onto roof of channel where staple fastener 172 shoots a unique
staple 174 which does not easily pull out around wire and into the
AAC.
[0156] The internal air duct system 180 of this invention, see
FIGS. 13A-13B, can be housed in the top beam 206A and structural
beam system. A PVC type pipe may be placed within the cementitious
material (AAC) which benefits the AAC by reducing its weight and
simultaneously reinforcing it, and further the AAC is benefits the
air duct by insulating it, hiding the duct system to enable easy
access for vents 181. The vents 181 can have various sizes for
openings as engineered for facilitating desired air flow, and
regulated by vent opening size and proximity to air return vents.
The system can be located at a centralized location and initial
service ducts run through a chase 184 shared by other main
utilities, and then hooked up to the internal duct system. The duct
corners 182, as seen in FIG. 13B, are installed by deep socket,
large tubular bit 185 which goes around exterior of air duct 180,
and creates a void 183. The duct is then cut back at a required
depth 166 to align with the duct in the adjoining piece, and the
AAC is cleared so that the corner coupling 182 slips into the void
and over the duct in the top beam 206A, and likewise in second top
beam 206A, thereby creating a continuous duct system with rounded
corners. A manufacturing process of creating void around the duct
is to have an inflatable sleeve 186 (FIG. 2K) placed on the pipe
while in the mold before slurry is introduced. After the mold is
removed, the sleeve is deflated and removed. At the site, by this
embodiment, the AAC is simply cut back as required and duct's
corner coupling 182 slipped on.
[0157] There is limited waste product with the AAC according to the
preferred practice of this invention, but what waste there is can
be easily handled by the machine 140 that can crush waste
cementitious pieces 142 into dust 141, so they do not have to be
taken to landfills. This means habitats manufactured by the instant
invention can be constructed with little or no waste AAC from the
site having to go to a landfill, thereby lessening construction
costs and providing an environmentally friendly practice. The
resulting dust may then be used as fertilizer 144 for grass, trees,
etc.
[0158] As blocks of AAC are set in place, excess mortar can be
forced out beyond the wall face. To solve this problem, FIGS. 15
and 15A show a joint finisher 150 according to the invention. The
joint finisher 150 has a unique roller 152 which serves several
useful functions, namely, keeps blade 151 at an optional angle for
removing excess AAC mortar from the block face at joints and the
roller smoothes out any residual trace amounts of mortar, while the
spring pressured cleaning blade 153 removes AAC which may
accumulate on the roller. The result, one tool replaces the prior
art's tools and motions.
[0159] The hand held finishing tool shown in FIG. 11D may be used
with a template guide so that an architecturally finished opening
results where there was once a wall. The window is simply slipped
in and caulked and/or finished nailed. No additional wood trim or
casing is required. The outlet and switch openings, beam notches,
etc. require a different type of template guide having prongs. The
guiding arms may be kept perpendicular by level bubble on the
support arm 160. In difficult positions, such as a corner notch, an
angled template is used and, as the rotor zip type tool goes around
a guide, a chunk of AAC is removed which allows the beam to seat
into the wall and be finished with mortar and screw.
[0160] It is recognized that changes, variations and modifications
may be made to the method of this invention, and to the securing
device, particularly by those skilled in the art, without departing
from the spirit and scope thereof Accordingly, no limitation is
intended to be imposed thereon except as set forth in the
accompanying claims.
* * * * *